Draka USAComparative Testing of

Longitudinally Corrugated vs. Helically Applied Shields for

Transit Applications

• PURPOSE OF TESTSPURPOSE OF TESTS

• ALTERNATIVE CONSTRUCTIONSALTERNATIVE CONSTRUCTIONS

• TEST SAMPLES MADETEST SAMPLES MADE

• TESTS CONDUCTEDTESTS CONDUCTED

• TEST RESULTSTEST RESULTS

• CONCLUSIONSCONCLUSIONS

Draka USA

DISCUSSION ITEMS

PURPOSE OF TESTSPURPOSE OF TESTS

          DEMONSTRATE EQUIVALENT PERFORMANCE TO DEMONSTRATE EQUIVALENT PERFORMANCE TO STANDARD CLASS 1 RAILROAD SIGNAL CABLE STANDARD CLASS 1 RAILROAD SIGNAL CABLE DESIGNS EMPLOYING HELICALLY APPLIED DESIGNS EMPLOYING HELICALLY APPLIED BRONZE TAPES.BRONZE TAPES.

              

Draka USA

PURPOSE OF TESTSPURPOSE OF TESTS

TEST PROGRAMTEST PROGRAM

            PURPOSE: EVALUATE ALTERNATIVESPURPOSE: EVALUATE ALTERNATIVES

            NUMBER OF ALTERNATIVES: 3NUMBER OF ALTERNATIVES: 3

            KEY PERFORMANCE ISSUES:KEY PERFORMANCE ISSUES:            FLEXIBILITYFLEXIBILITY

DURABILITYDURABILITY

Draka USA

CONSTRUCTIONSCONSTRUCTIONS

CURRENT ARMORED SIGNAL CABLE:CURRENT ARMORED SIGNAL CABLE:

EPR INSULATIONEPR INSULATION

TINNED COPPER CONDUCTORSTINNED COPPER CONDUCTORS

SBR TAPE or BEDDING LAYERSBR TAPE or BEDDING LAYER

HELICAL BRONZE TAPEHELICAL BRONZE TAPE

PE, NEOPRENE OR LSZH JACKETPE, NEOPRENE OR LSZH JACKET

Draka USA

CONSTRUCTIONSCONSTRUCTIONS

PROPOSED ARMORED SIGNAL CABLE:PROPOSED ARMORED SIGNAL CABLE:

EPR INSULATIONEPR INSULATION

TINNED COPPER CONDUCTORSTINNED COPPER CONDUCTORS

SBR TAPE or BEDDING LAYERSBR TAPE or BEDDING LAYER

LONGITUDINAL CORRUGATED BRONZE LONGITUDINAL CORRUGATED BRONZE SHIELDSHIELD

PE, NEOPRENE OR LSZH JACKETPE, NEOPRENE OR LSZH JACKET

Draka USA

ALTERNATIVE ALTERNATIVE CONSTRUCTIONSCONSTRUCTIONS

ALT. 1: MYLAR/LC BRONZE SHIELDALT. 1: MYLAR/LC BRONZE SHIELD

MYLAR TAPEMYLAR TAPE

LONGITUDINALLY APPLIED, CORRUGATED, LONGITUDINALLY APPLIED, CORRUGATED, BRONZE SHIELDBRONZE SHIELD

ALT. 2: SBR/LC BRONZE SHIELDALT. 2: SBR/LC BRONZE SHIELD

SBR TAPESBR TAPE

LONGITUDINALLY APPLIED, CORRUGATED, LONGITUDINALLY APPLIED, CORRUGATED, BRONZE SHIELDBRONZE SHIELD

ALT. 3: SBR/LC STEEL SHIELDALT. 3: SBR/LC STEEL SHIELD

SBR TAPESBR TAPE

LONGITUDINALLY APPLIED, CORRUGATED, STEEL SHIELDLONGITUDINALLY APPLIED, CORRUGATED, STEEL SHIELD

Draka USA

TEST SAMPLES TEST SAMPLES MANUFACTUREDMANUFACTURED

SAME CABLE CORE AND JACKET FOR ALL FOUR SAME CABLE CORE AND JACKET FOR ALL FOUR SAMPLES:SAMPLES:

5 Conductors5 Conductors

Tinned copperTinned copper

EPR InsulationEPR Insulation

78 MIL PE Jacket78 MIL PE Jacket

Draka USA

TEST SAMPLES TEST SAMPLES MANUFACTUREDMANUFACTURED

STANDARD CONSTRUCTION:STANDARD CONSTRUCTION:

SBR TAPESBR TAPE

10 MIL HELICAL, BRONZE SHIELD10 MIL HELICAL, BRONZE SHIELD

ALT. 1: MYLAR/LC BRONZE SHIELDALT. 1: MYLAR/LC BRONZE SHIELD

MYLAR INSTEAD OF SBR TAPEMYLAR INSTEAD OF SBR TAPE

LC INSTEAD OF HELICAL SHIELDLC INSTEAD OF HELICAL SHIELD

ALT. 2: SBR/LC BRONZE SHIELDALT. 2: SBR/LC BRONZE SHIELD

LC INSTEAD OF HELICAL SHIELDLC INSTEAD OF HELICAL SHIELD

ALT. 3: SBR/LC STEEL SHIELDALT. 3: SBR/LC STEEL SHIELD

6 MIL COATED, LC STEEL SHIELD6 MIL COATED, LC STEEL SHIELD

Draka USA

TESTS CONDUCTEDTESTS CONDUCTED

CRUSH TESTCRUSH TEST

Measures compressive force needed to cause electrical failureMeasures compressive force needed to cause electrical failure

CYCLIC FLEXING TESTCYCLIC FLEXING TEST

Measures capability of cables to withstand multiple flexesMeasures capability of cables to withstand multiple flexes

FLEXIBILITY TESTFLEXIBILITY TEST

Measures force required for a single bendMeasures force required for a single bend

CUT THROUGH TESTCUT THROUGH TEST

Measures the force on a 90Measures the force on a 90oo wedge required to cut through to wedge required to cut through to the armor and to the conductors the armor and to the conductors

Draka USA

CRUSH TEST APPARATUSCRUSH TEST APPARATUSDraka USA

Side view of area shown above enclosed within dotted lines.

Load Cell

Cable Under Test

Tensile Test Machine

Crosshead movement at0.50 inches per minute

Crosshead

3/4 inch Steel Mandrel

Continuity testers, monitoringfor shorts between cable

components and testapparatus.

3/4 inch Steel MandrelIndicates directionof movment and

compressive force

Cable Under Test

CRUSH TEST RESULTS

CABLECABLE FORCE (LB) AT FAILURE FORCE (LB) AT FAILURE

TYPETYPE AVE.AVE. MIN.MIN.

STD.STD. 9,0009,000 7,000 7,000

ALT. 1ALT. 1 > 10,000> 10,000 > 10,000> 10,000

ALT. 2ALT. 2 9,1009,100 8,3008,300

ALT. 3ALT. 3 9,5009,500 8,6008,600

Draka USA

CRUSH TEST RESULTS

TEST CONDITIONS:TEST CONDITIONS:

ONE 4 FT. SAMPLE PER TYPEONE 4 FT. SAMPLE PER TYPE

TEN APPLICATION POINTS PER SAMPLETEN APPLICATION POINTS PER SAMPLE

LOAD RATE: 0.5 IN/MIN.LOAD RATE: 0.5 IN/MIN.

MAX. APPLIED FORCE: 10,000 LB.MAX. APPLIED FORCE: 10,000 LB.

FAILURE WHEN SHORT DETECTEDFAILURE WHEN SHORT DETECTED

Draka USA

CYCLIC FLEXING TEST APPARATUS Draka USA

55 lbWeight

90° 90°

7 inch Rollers

8½in.

Cable under test, withconductors and armorconnected in series.

Continuity monitor,stops machine fromflexing cable when

open circuit isdetected

Lower Rollers, tostabilize cableduring flexing

CYCLIC FLEXING TEST RESULTS CABLE TYPE NO. OF CYCLES DESCRIPTION OF FAILURE____CABLE TYPE NO. OF CYCLES DESCRIPTION OF FAILURE____

STDSTD 233233 CONTINUITY LOST IN ONE CONTINUITY LOST IN ONE COND.COND.

426426 JACKET SPLIT OPEN JACKET SPLIT OPEN

   538538 JACKET & ARMOR SEVERELY JACKET & ARMOR SEVERELY SPLITSPLIT

ALT. 1ALT. 1 230230 CONTINUITY LOST IN ARMOR CONTINUITY LOST IN ARMOR

   282282 CONTINUITY LOST IN ONE CONTINUITY LOST IN ONE COND.COND.

ALT. 2ALT. 2 316316 CONTINUITY LOST IN ONE CONTINUITY LOST IN ONE COND.COND.

   482482 CONTINUITY LOST IN ARMOR CONTINUITY LOST IN ARMOR

ALT. 3ALT. 3 260260 JACKET SPLIT OPEN JACKET SPLIT OPEN

   288288 CONTINUITY LOST IN ONE CONTINUITY LOST IN ONE COND.COND.

   322322 CONTINUITY LOST IN ARMOR CONTINUITY LOST IN ARMOR

Draka USA

CYCLIC FLEXING TEST RESULTS

TEST CONDITIONS:TEST CONDITIONS:

ONE 3 FT. SAMPLE PER TYPEONE 3 FT. SAMPLE PER TYPE

ONE CYCLE: TWO 90ONE CYCLE: TWO 90OO BENDS BENDS

15 CYCLES PER MIN.15 CYCLES PER MIN.

Draka USA

FLEXIBILITY TEST APPARATUS Draka USA

Side view of area shown above enclosed within dotted lines.

Steel Cable

Load Cell

Cable Under Test

Tensile Test Machine

Crosshead

Crosshead movement at20 inches per minute

Cable Clamp

Steel Cable

2.8 inch Mandrel

Cable clamps spaced 24" apart

Cable Under Test

Crosshead

FLEXIBILITY TEST RESULTS Draka USA

1

1

2

2

3

4

34

NO. 1 -- NO. 1 -- STANDARD TYPESTANDARD TYPE

NO. 2 -- NO. 2 -- ALTERNATIVE TYPE 1ALTERNATIVE TYPE 1

NO. 3 -- NO. 3 -- ALTERNATIVE TYPE 2ALTERNATIVE TYPE 2

NO. 4 -- NO. 4 -- ALTERNATIVE TYPE 3ALTERNATIVE TYPE 3

FLEXIBILITY TEST RESULTS

TEST CONDITIONSTEST CONDITIONS

ONE SAMPLE PER TYPEONE SAMPLE PER TYPE

SINGLE BEND, 90SINGLE BEND, 90OO

2.8 INCH MANDREL2.8 INCH MANDREL

RATE: 20 INCHES PER MIN.RATE: 20 INCHES PER MIN.

Draka USA

CUT THROUGH TEST APPARATUS

Draka USA

Side view of area shown above enclosed within dotted lines.

Load Cell

Cable Under Test

Tensile Test Machine

Crosshead movement at0.50 inches per minute

Crosshead

3/4 inch Steel Wedge

Continuity testers, monitoringfor shorts between cable

components and testapparatus.

3/4 inch Steel WedgeIndicates directionof movment and

compressive force

Cable Under Test

CUT THROUGH TEST RESULTS

CABLECABLE AVE. FORCE (LB) TO REACHAVE. FORCE (LB) TO REACH

TYPETYPE ARMORARMOR CONDUCTORCONDUCTOR

STD.STD. 2,8002,800 5,0005,000

ALT. 1ALT. 1 3,1003,100 5,1005,100

ALT. 2ALT. 2 3,1003,100 5,0005,000

ALT, 3ALT, 3 4,3004,300 4,7004,700

  

Draka USA

CUT THROUGH TEST RESULTS

TEST CONDITIONS:TEST CONDITIONS:

ONE 4 FT. SAMPLE PER TYPEONE 4 FT. SAMPLE PER TYPE

TEN APPLICATION POINTS PER SAMPLETEN APPLICATION POINTS PER SAMPLE

LOAD RATE: 0.5 IN/MIN.LOAD RATE: 0.5 IN/MIN.

MAX. APPLIED FORCE: 10,000 LB.MAX. APPLIED FORCE: 10,000 LB.

SHORT TO WEDGE DETECTEDSHORT TO WEDGE DETECTED

Draka USA

CONCLUSIONS CRUSH TESTCRUSH TEST

MYLAR TAPE WITH LONGITUDINAL CORRUGATED BRONZE MYLAR TAPE WITH LONGITUDINAL CORRUGATED BRONZE SHIELD SIGNIFICANTLY BETTERSHIELD SIGNIFICANTLY BETTER

CYCLIC FLEXING TESTCYCLIC FLEXING TEST

NO SIGNIFICANT DIFFERENCESNO SIGNIFICANT DIFFERENCES

FLEXIBILITY TESTFLEXIBILITY TEST

THE LONGITUDINAL SHIELD IS AS FLEXIBLE AS THE HELICALTHE LONGITUDINAL SHIELD IS AS FLEXIBLE AS THE HELICAL SHIELDSHIELD

CUT THROUGH TESTCUT THROUGH TEST

HELICAL SHIELD SLIGHTLY LESS RESISTANT TO CUT HELICAL SHIELD SLIGHTLY LESS RESISTANT TO CUT THROUGHTHROUGH

Draka USA

RECOMMENDATION

ALLOW THE USE OFALLOW THE USE OF

MYLAR TAPE ANDMYLAR TAPE AND

10 MIL, LONGITUDINAL10 MIL, LONGITUDINAL

CORRUGATED BRONZE SHIELDCORRUGATED BRONZE SHIELD

IN UNDERGROUND SIGNAL CABLEIN UNDERGROUND SIGNAL CABLE

Draka USA

BENEFITS

ANNUAL COST SAVINGSANNUAL COST SAVINGS

NO REDUCTION IN PERFORMANCE NO REDUCTION IN PERFORMANCE 

SAFER HANDLING DURING TERMINATIONSAFER HANDLING DURING TERMINATION

Draka USA